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Data Bulletin

8800DB0404 11/2004 Raleigh, NC, USA

Altivar® 58 TRX Quality Assurance Test Procedures

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INTRODUCTION

Schneider Electric performs extensive quality assurance tests on Altivar 58 TRX (ATV58 TRX) adjustable frequency drive controllers at the production facilities in the USA and Japan. These tests verify the integrity of the assembly process, detect premature component failures, and gather product quality data. This product data bulletin describes typical inspections and tests conducted on all drive controllers. Table 1 provides frame size references based on configuration and voltage ratings. Table 1: ATV58 TRX Frame Size, Configuration, & Voltage Ratings

Constant Torque 208/230 V

0.5­1 hp 2­3 hp 4­5 hp 5­10 hp -- 10­20 hp 20­40 hp -- -- --

ATV58 Frame Size

1 2 3 4 5 6 7 8 9 10

Variable Torque 208/230 V

0.5­1 hp 2­3 hp 4­5 hp 5­10 hp -- 10­25 hp 20­50 hp -- -- --

460 V

-- 1­3 hp 4­7.5 hp 10­15 hp 20 hp 20­40 hp 40­75 hp -- 100­150 hp 200­350 hp

460 V

-- 1­3 hp 4­10 hp 10­20 hp 20­25 hp 25­50 hp 50­100 hp 125 hp 150­250 hp 300­500 hp

TEST PROCEDURES

This section lists the ATV58 TRX quality assurance test procedures. All printed wiring circuit board assemblies are fabricated and tested in production facilities around the world. The tests performed at these locations include:

· ·

In-circuit, component-level testing High-potential test applied to high-voltage boards for one second

Each test station has manufacturing instructions for a visual quality checklist. This check includes a physical inspection for proper connections, power semiconductor polarities, proper mounting torques, and proper wiring. The compression connections and assemblies are also checked for mechanical integrity.

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Altivar® 58 TRX Quality Assurance Test Procedures

8800DB0404 11/2004

High-Potential Test for Frame Sizes 1­10

After each device is placed in the test station, the operator scans in the bar coded serial numbers and starts the test sequence. The system performs the following: 1. Checks the safety interlocks before applying power to the drive controller. 2. Applies high voltage for one second between various points within the drive controller. 3. Writes the proper pass or fail flag to the network for tracking.

Control Test 1 for Frame Sizes 1­10

After each device is placed in the test station, the operator scans in the bar coded serial number and starts the test sequence. The system performs the following: 1. Checks the safety interlocks before applying power to the drive controller. 2. Checks the internally-generated supplies to verify that the switch-mode power supply is operating. 3. Determines the test parameters appropriate for the drive based on its serial number. 4. Checks the network flags to verify that the drive controller has passed the high potential test. 5. Checks for the proper software version and checksums. 6. Verifies operation of the logic inputs and relay outputs, and performs calibration of the analog inputs. 7. Verifies operation of the DC bus pre-charge sequence. 8. Gates the IGBTs in pairs and verifies conduction. 9. Verifies operation of internal fans. 10. Verifies operation and performs calibration of all current and voltage feedback circuits. 11. Verifies operation of internally-generated fault signals. 12. For frame sizes 1­7, verifies proper motor operation in forward and reverse directions. The motors are loaded with 1X inertial loads (a load equal to the inertia of the rotor in the motor). The drive controller, set to a minimum ramp time of 0.1 seconds, is then rapidly accelerated and decelerated to provide maximum di/dt and dv/dt stress to the power semiconductors. 13. For frame sizes 8­10, two load types are used to verify proper operation. A static inductive load is first used to check the output voltage characteristics (at 10 Hz and 60 Hz) and the output current balance. Then, the drive controller is attached to a motor/generator set which is adjusted to give the rated load. The output voltage characteristics and output current balance checks are made once again at 60 Hz output frequency and rated current load. 14. Writes the proper pass or fail flag to the network for tracking.

2

© 2004 Schneider Electric All Rights Reserved

8800DB0404 11/2004

Altivar® 58 TRX Quality Assurance Test Procedures

Burn-In Test for Frame Sizes 1­7

After each device is placed in a test cart, the operator scans in the bar coded serial number and cart serial number. The cart is then loaded into the thermal chamber, and the operator starts the test sequence. The system performs the following: 1. Checks the safety interlocks before applying power to the drive controller. 2. Begins a short dwell at 25 °C. During this dwell, the system checks the network flags to verify that the drive controller has passed Control Test 1 and records the chamber number and shelf position. 3. The drive controllers are then subjected to the following temperatures: -- high temperature dwell at 55 °C for 20 minutes for frame sizes 1­5 -- high temperature dwell at 45 °C for 30 minutes for frame sizes 6­7 -- low temperature dwell at 0 °C for 5 minutes -- temperature ramp set at 4°C per minute 4. During the above temperature excursions, the drive controllers are subjected to the following power cycles: -- power on for 90 seconds -- power off for 15 seconds -- power cycled continuously, except during negative temperature ramp 5. During the above power on cycles, the drive controllers are subjected to the following load cycles: -- run forward for 10 seconds at 0.1-second ramp rate -- run reverse for 10 seconds at 0.1-second ramp rate -- load cycled continuously during power-on time, after 15-second delay at power-on 6. During the above load cycles, the system constantly monitors drive frequency, motor current, heat-sink temperature, and calculated motor temperature. Frame sizes 1­5 devices are burned in for a period of forty-five minutes. Frame sizes 6­7 devices are tested for 1.5 hours with the same load cycle parameters. 7. Upon completion of the required number of thermal cycles (one for frame sizes 1­5, two for frame sizes 6 and 7) or upon a failure, the following data are automatically stored in the network for tracking: -- the number of cycles completed -- the number of times through test -- the failure code or pass code

Burn-In Test for Frame Sizes 8­10

Frame sizes 8­10 devices are operated continuously at 100% load in a 50 °C ambient for a period of two hours. Test data is recorded and stored in the network for tracking at the end of the burn-in cycle.

© 2004 Schneider Electric All Rights Reserved

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Altivar® 58 TRX Quality Assurance Test Procedures

8800DB0404 11/2004

Control Test 2 for Frame Sizes 1­10

After the burn-in cycle, each device is replaced in the test station. The operator scans in the bar coded serial number and starts the test sequence. The system performs the same test as in "Control Test 1 for Frame Sizes 1­10" on page 2. The system, also checks the network flags to ensure that the drive has passed burn-in.

Final Inspections Certificate of Conformance

Completed drive controllers are visually inspected at the packaging station prior to shipment. Upon request, Schneider Electric will issue a Certificate of Conformance, which adheres to the guidelines of ANSI N45.2.10-1973, and certifies that the drive controller was manufactured and tested under NEMA Standards ICS 1-2000, Section 8.10.1, Production Tests; and Section 8.10.2, Performance Tests.

Schneider Electric USA 8001 Highway 64 East Knightdale, NC 27545 USA 1-888-SquareD (1-888-778-2733) www.us.SquareD.com

Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material. © 2004 Schneider Electric All Rights Reserved

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